EP3581344B1 - System und verfahren für robotisches manipulatorsystem - Google Patents

System und verfahren für robotisches manipulatorsystem Download PDF

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Publication number
EP3581344B1
EP3581344B1 EP19185233.4A EP19185233A EP3581344B1 EP 3581344 B1 EP3581344 B1 EP 3581344B1 EP 19185233 A EP19185233 A EP 19185233A EP 3581344 B1 EP3581344 B1 EP 3581344B1
Authority
EP
European Patent Office
Prior art keywords
rma
robotic arm
operator
sensors
virtual barrier
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP19185233.4A
Other languages
English (en)
French (fr)
Other versions
EP3581344A1 (de
Inventor
Scott Martin
Paul Linnebur
Marc Rood
Matt Cole
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Veolia Nuclear Solutions Inc
Original Assignee
Kurion Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kurion Inc filed Critical Kurion Inc
Priority to EP21206720.1A priority Critical patent/EP3970924B1/de
Publication of EP3581344A1 publication Critical patent/EP3581344A1/de
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Publication of EP3581344B1 publication Critical patent/EP3581344B1/de
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Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J18/00—Arms
    • B25J18/02—Arms extensible
    • B25J18/025—Arms extensible telescopic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
    • B25J13/086—Proximity sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J13/00—Controls for manipulators
    • B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
    • B25J13/088—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices with position, velocity or acceleration sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/0009—Constructional details, e.g. manipulator supports, bases
    • B25J9/0018—Bases fixed on ceiling, i.e. upside down manipulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/02—Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian coordinate type
    • B25J9/04—Programme-controlled manipulators characterised by movement of the arms, e.g. cartesian coordinate type by rotating at least one arm, excluding the head movement itself, e.g. cylindrical coordinate type or polar coordinate type
    • B25J9/045—Polar coordinate type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1674—Programme controls characterised by safety, monitoring, diagnostic
    • B25J9/1676—Avoiding collision or forbidden zones
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/39—Robotics, robotics to robotics hand
    • G05B2219/39226—Operational space formulation, project model into cartesian coordinates

Definitions

  • This disclosure relates generally to robotic systems designed to perform operations in hazardous and/or difficult to access spaces.
  • Certain industrial project environments are hazardous to humans, and generally require workers to wear protective clothing and a breathing apparatus to enter and work in the area. Also, the space or area for certain projects is often not designed with human movement in mind, meaning the space can be too small, too hot, too cold, or generally difficult or impossible for humans to navigate. Some industrial project areas are so hazardous and difficult to access that human entry and repairs are altogether unfeasible. To gain access to such areas, and to reduce human exposure to hazardous conditions, remote robotic manipulators are a necessity.
  • WO 2013/164622 A1 shows a system for manipulating an object using a haptic manipulator for operating a robotic arm and end effector.
  • the robotic arm copies the movements of the manipulator via a force-feedback 3D joystick.
  • the end effector carries a scalpel blade that cuts through a reflective tissue layer and a dark tissue layer. When the scalpel cuts through the reflective layer, a feedback force to the manipulator is relatively low. When the scalpel starts to move outside of the reflective layer and into the dark layer, the feedback force to the manipulator is relatively high.
  • US 6 645 196 B1 shows a tool changing method for surgical tools that include bodies and end effectors that each have a distal end.
  • a remotely operable robotic manipulator arm is disclosed.
  • the RMA may be used to remotely inspect, maintain, and clean difficult to access and/or hazardous spaces of a variety of different shapes, sizes, and technical constraints with little to no direct human interaction required.
  • the RMA is versatile, durable, reusable, decreases operational risk, and increases operator safety.
  • the RMA may be one or more of radiation resistant, temperature tolerant, freeze protected, humidity tolerant, chemical resistant, and seismic/wind/weather tolerant, among others.
  • the RMA in some embodiments is designed and configured such that it can be transported and installed in existing locations without affecting pre-existing infrastructure or requiring heavy machinery.
  • the RMA may be installed and deployed within extremely tight quarters.
  • deployment of the RMA does not require expensive or specialized tooling.
  • the RMA carriage in some embodiments may follow a specific cam path allowing the manipulator to travel vertically up and down through an access point.
  • Manual deployment in some embodiments can be carried out quickly and efficiently, limiting worker exposure to the area of operations. After the RMA has completed operations, it may be washed down on site, retrieved from the workspace, and may be removed from the site in the reverse order in which it was installed. The RMA may be redeployed at the same or other sites.
  • the workspace in some embodiments may variously contain one or more of ion exchange resin, sludge, effluent, toxic waste, and other potentially hazardous and/or difficult to remove materials.
  • the purpose of the RMA is to facilitate the necessary operations to inspect workspaces, remove any remaining materials, clean the workspace, and install or uninstall devices in the space, among other operations.
  • the RMA may allow for the attachment of various standard and/or customized tools that may be maneuvered within workspaces to carry out a variety of differing operations.
  • the RMA can remove bulk ion exchange material and sand using a suction tool while being fully submerged in effluent.
  • FIG. 1 depicts an isometric view of an embodiment of a robotic manipulator arm (RMA) 100 when partially extended.
  • the RMA 100 in some embodiments is operable to carry out inspection, maintenance, repairs, and cleaning operations in difficult to access and/or hazardous environments.
  • the RMA 100 in the depicted embodiment comprises a support frame 10, carriage 115, mast 120, forearm 130, elbow 140, wrist 150, and an end effector 160.
  • Some embodiments may comprise additional components, or more than one of one or more of the depicted components.
  • at least one of the mast and forearm are extendable by means such as telescoping.
  • the degrees of freedom for the depicted embodiment are vertical mast extension/retraction, mast rotation, elbow pivots, forearm extension/retraction, wrist pitch, and wrist roll.
  • additional tools and carts may be used depending on the application and project requirements.
  • the RMA 100 is sized and configured to be transportable. In some embodiments, the RMA 100 is designed to be easily maneuvered through existing rooms and doors, taking into consideration constraints comprising limited head room, access in and out of doorways, existing equipment and infrastructure, and access points.
  • the RMA 100 may be scaled to its intended application. In an embodiment, the RMA 100 has a vertical reach of 32 feet and a horizontal reach of 15 feet when fully extended. Other versions of vertical and horizontal reach are possible depending on how the RMA is scaled to its intended application.
  • integration of carbon fiber and other lightweight materials minimizes the overall weight of the RMA 100 while retaining a high payload capacity.
  • the payload capacity of the RMA 100 is up to 100 lbs. at full reach and up to 150 lbs. in specific orientations.
  • the RMA 100 is scalable for differing operations and environments thus a wide range of payload capacities are possible.
  • Figure 2 depicts an embodiment of an RMA 100 housed in a support frame 10.
  • the RMA 100 fits completely within the support frame 10 when it is fully collapsed thus increasing maneuverability of the system during deployment and retrieval and decreasing the storage footprint.
  • the support frame 10 may comprise wheels or some other such mechanism to facilitate transportation and positioning.
  • the support frame 10 when the support frame 10 is positioned, it may be mounted to external supports 105 to increase system stability during deployment of the manipulator arm.
  • the support frame 10 may provide containment for at least one of operation, wash-down, and transportation.
  • a carriage 115 may be used to couple the RMA 100 to the support frame 10 during operations.
  • the carriage 115 in some embodiments may integrate a cam path 112 and/or a rotary actuator to control the alignment of the RMA 100 as it is deployed.
  • the rotary actuator is hydraulic.
  • the carriage 115 may comprise control componentry for operation and control of the RMA 100 such as electric wire rope winches, position feedback, and motors for mast extension and/or rotation.
  • the carriage 115 further serves the purpose of cable management.
  • FIGS 3A through 3H depict an embodiment of an RMA 100 deployment process.
  • Figure 3A depicts an RMA 100 at the beginning of deployment when the working end of the manipulator arm has been inserted into the access point.
  • the access point is below the RMA 100.
  • the RMA 100 may be configured to deploy through access points that are in walls, ceilings, or other structures. In some embodiments, the RMA 100 may be deployed in open environments.
  • Figures 3B through 3E depict the RMA 100 as the forearm 130 is entering the access point.
  • a cam and cam path may be used to control the angle(s) at which the RMA 100 is deployed into the access point.
  • a cam and cam path are used to keep the manipulator vertical as it enters the access point below it.
  • the carriage 115 is rotated up using a cam mechanism as the forearm 130 is deployed into the access point.
  • the mast is first rotated upward to 90° ( FIGS. 3B and 3C ) then lowered ( FIGS. 3D and 3E ) to the bottom of the frame 10.
  • Figure 3F and 3G depict the RMA 100 as an elbow 140 is entering the access point and the carriage 115 is rotated upward another 90°.
  • the carriage 115 rotates 180° during the deployment process. Once the carriage 115 is 180° from its original position the mast may be deployed through the access point as depicted in Figures 4A and 4B .
  • the RMA 100 in some embodiments utilizes a cart to facilitate transportation and/or installation.
  • a cart may allow the RMA 100 to be laid down on its side (horizontally) and may optionally include a bar linkage or other such mechanism to aid in moving the RMA 100 from a horizontal to a vertical orientation and vice versa. Once in position, the optional bar linkage may be actuated to power one or more onboard hydraulic cylinders. When the frame is in the upright (vertical) position and located over the workspace, the cart may be removed.
  • the RMA 100 frame incorporates a number of wheels, and/or one or more other mobility facilitating mechanisms, to allow the RMA 100 to be transported and positioned.
  • the RMA 100 may be manually positioned or positioned using remote control.
  • the installation cart may comprise one or more drive mechanisms to allow for remote operation of the cart for proper positioning.
  • the RMA 100 may be mounted to pre-existing infrastructure, or other supports, to increase stability during deployment of the manipulator.
  • the RMA 100 comprises a mounting plate which may be secured to existing infrastructure.
  • the mounting plate may be secured to the floor for a floor access point such that the load path is directed through the mounting plate to the floor rather than through the frame.
  • the manipulator in some embodiments may use an overhead A-frame gantry beam and chain falls or other lifting mechanism.
  • the RMA 100 may be unfolded into an access point either while powered or unpowered.
  • Some embodiments comprise a cam and cam path for controlling motion of deployment for difficult access points.
  • the RMA 100 carriage may follow a specific cam path allowing the manipulator to travel linearly into an access point.
  • Figure 4A depicts an embodiment of the mast 120 in a retracted position.
  • the mast 120 may comprise one or more telescoping tubes.
  • the mast 120 in some embodiments may be extended or retracted depending on the desired depth/height as shown in Figure 4B .
  • one or more tubes are formed from light material such as carbon fiber.
  • one or more tubes are composed of metal such as stainless steel.
  • the mast 120 may be securely mounted to the carriage 115 by means of mounting rings and bearings coupled to the outermost tube.
  • the mast 120 is capable of rotating 360°.
  • the innermost tube may comprise a hydraulic cylinder which may form or couple to an elbow mechanism. In the depicted embodiment, the hydraulic cylinder is double-acting.
  • Figure 5 depicts an embodiment of the elbow 140 which may be used to couple a mast 120 to a forearm 130.
  • the elbow 140 is a two-stage actuation.
  • the elbow 140 allows for a total of -10° to +180° of motion from vertically down.
  • the mast-elbow pivot 141 of the elbow allows for 90° of motion to allow the elbow linkage to be oriented down or horizontal.
  • the forearm-elbow pivot 142 allows for 100° of motion, for instance -10° to +90° of actuation.
  • Figure 6A depicts an embodiment of the elbow 140 oriented directly downwards.
  • Figure 6B shows a 90° actuation of the mast-elbow pivot 141 lifting the forearm 130 to a horizontal position.
  • Figure 6C shows an example 90° actuation of the forearm-elbow pivot 142 that lifts the forearm 130 to a vertical position.
  • the combination of these actuations may allow the RMA 100 to reach the full extents of the workspace.
  • each stage is actuated using a single hydraulic cylinder, and each pivot pin incorporates a resolver for position feedback.
  • stage actuation may require multiple hydraulic cylinders.
  • a double-acting hydraulic cylinder is mounted within the inner- mast 120 and provides pivot motion for a first elbow joint 141.
  • the hydraulic cylinder assembly may comprise a stainless-steel rod and cylinder weldment.
  • the hydraulic cylinder may attach to the end of the mast 120 by means of a pin.
  • the RMA 100 may comprise one or more joints. In some embodiments, all the joints actuate in the same plane.
  • the joints in some embodiments may be offset to actuate in different planes or at different angles with respect to each other. Different joint types with different ranges of motion may be implemented, such as ball joints and chain joints.
  • Chain joints are described in co-pending patent application entitled Systems and Methods for Chain Joint Cable Routing, Ser. No. 14/975,544 filed December 18, 2015, with a priority date of December 19, 2014 , which is hereby incorporated by reference in its entirety.
  • one or more of the joints may be hydraulically actuated.
  • the forearm 130 is similar in design to the mast.
  • the forearm 130 comprises one or more telescoping tubes.
  • the one or more tubes may be composed of carbon fiber.
  • one or more tubes is composed of metal such as stainless steel.
  • Figure 7A depicts the forearm 130 in a retracted position and Figure 7B depicts the forearm 130 in an extended position.
  • the telescoping forearm 130 may extend and retract using one or more hydraulic cylinders which may be ported together to allow them to actuate at the same time, in some embodiments.
  • the cylinder rods may be hollow to minimize the number of hydraulic lines required to run through the forearm 130.
  • the forearm pivot actuation is provided by one or more elbows.
  • bushings may be utilized to prevent rotation of the mast and/or forearm tubes with respect to each other.
  • the tubes may be equipped with dual keys and matching key slots in the bushings to keep the sections from rotating independently.
  • the bushings may have slots machined into them to allow wash-down water to flow through.
  • Hard stops may be incorporated into one or more of the tubes to prevent over-extension or over-retraction.
  • retraction hard stops screw into the top of each keyway.
  • one or more interfaces between telescoping tools and other componentry may be coated or comprised of low friction material to facilitate motion.
  • the telescoping mast and/or forearm may extend using gravity.
  • the mast and/or forearm may be retracted using a rope, tether, or other flexible attachment which may be connected to a winch or hoist mechanism.
  • the retraction may be effected using one or more electrically driven wire rope hoists.
  • the mast and/or forearm in some embodiments include one or more redundant wire rope hoists for failure recovery. Each hoist may be capable of retraction on its own in the case another fails. Wire rope hoists may position the mast and/or forearm along its stroke, as desired by the operator.
  • the RMA 100 comprises a wrist joint 150 at the working end of the forearm 130.
  • Figure 8A through 8C depict an example range of motion of the wrist 150.
  • the wrist 150 in some embodiments may be capable of one or more actuations including a wrist pitch and a wrist roll.
  • the wrist 150 may comprise one or more rotary actuators that enable wrist roll and pitch.
  • the wrist pitch may be actuated using a hydraulic rotary actuator for +90° of motion in the vertical plane, in some embodiments.
  • the wrist roll may utilize a hydraulic rotary actuator and is capable of 180° of rotation, in some embodiments.
  • each joint in the wrist 150 is capable of up to 180° of rotation.
  • the wrist 150 comprises a master tool changer assembly.
  • the wrist 150 may comprise a universal grip or other mechanism to allow for deployment of a variety of tools and/or end effectors.
  • FIG. 9A depicts a rear isometric view of an embodiment of a gripper 160 comprising an embodiment of an end effector coupling mechanism 165 that can be used to connect and secure an end effector to a forearm 130.
  • Figure 9B depicts a front isometric view of the forearm 130 comprising an embodiment of a forearm coupling mechanism 155 that couples and secures an end effector 160 to the forearm 130.
  • the coupling mechanism is adapted for quick attach and release to allow for rapid end effector switching.
  • the coupling mechanism may comprise one or more of mechanical, electrical, and hydraulic connections.
  • the coupling mechanism may comprise means for materials transfer into and out of the workspace such as tubing.
  • the coupling mechanism is adapted to provide power, control, and materials transfer capabilities for a variety of different end effectors.
  • Figure 9C depicts the coupling mechanism embodiments of FIGS. 10A and 10B when coupled and the wrist is bent 90° downward.
  • Figure 9D depicts the coupling mechanism embodiments of FIGS. 10A and 10B when coupled and the wrist is bent 90° upward.
  • FIGS 10A and 10B depict front and rear isometric views of an embodiment of a gripper 160.
  • the gripper 160 may be capable of grasping objects and deploying a variety of tools.
  • the jaws 161 may be coupled to a linkage 162 to ensure they remain parallel during opening and closing.
  • the gripper 160 in the event of a hydraulic failure, the gripper 160 may fail in its "as-is" position. If pressure is lost the jaws 161 may become compliant and able to move if a predefined load is applied to the jaws 161.
  • a reduced stroke piston is used for smaller access points keeping the gripper 160 from opening to a size greater than a predetermined limit.
  • a gripper 160 can employ a wide variety of tools that may be used in different applications.
  • a gripper 160 may be used in conjunction with another tool, end effector, and/or one or more sensors. This may be useful in instances where the gripper 160 may be used to grasp infrastructure and provide stability to the tool or other end effector.
  • Some embodiments may comprise other tool/end effector/sensor configurations as needed for the desired operations.
  • the end effector may be a specific tool.
  • end effectors are actuated by one or more of mechanical, electromechanical, hydraulic, electric over hydraulic, pneumatic, magnetic, piezoelectric, and linear motor actuator.
  • each tool or end effector comprises a mounting interface that allows it to be grasped by a gripper 160 in one or more different orientations.
  • a mounting interface that allows it to be grasped by a gripper 160 in one or more different orientations.
  • One such interface is shown and described in co-pending application System and Method for Inspection and Maintenance of Hazardous Spaces, Ser. No. 15/341,985 filed November 2, 2016, with a priority date of November 3, 2015 , which is hereby incorporated by reference in its entirety.
  • the RMA 100 can perform a multitude of different operations by deploying a variety of different tools and end effectors.
  • the tools deployed by the RMA 100 may comprise off-the-shelf tools that may be modified for remote deployment, in some embodiments.
  • the RMA 100 may comprise any one or more of waterjet tool, inflatable bag tool, grout tool, shear tool, eductor bulk retrieval tool, jet wash tool, scoop/scraper tool, swabbing tool, gamma monitor, and other tools, end effectors, and sensors for carrying out one or more of inspection, maintenance, repairs, and cleaning.
  • a number of other tools are possible including simple tools such as rake, trowel, shovel, and the like.
  • Figures 11A through 11C depict an embodiment of a tool changing process.
  • the end effector 160 is inserted under the RMA 100 with the use of a tool handling system 210.
  • the end effector 160 is placed in-line with the retracted forearm 130.
  • the wrist coupling mechanism 155 is engaged to the end effector coupling mechanism 165 and secures the end effector 160 to the forearm 130.
  • Figure 12 shows an embodiment of the RMA 100 coupled to an end effector 160.
  • Figure 13 depicts an isometric view of the end effector 160 and forearm 130 coupled with a waterjet tool 180.
  • the tooling may be deployed into the workspace through separate access points which may be offset from the primary access point.
  • additional tools or end effectors may be placed in the workspace prior to RMA entry.
  • the tools and end effectors may be changed outside of the workspace.
  • Tools and end effectors may be lowered into the workspace using a hoist and/or pulley system in some embodiments.
  • a wire rope, or other such connector may be tensioned and retracted by the RMA 100 as needed.
  • a wire rope, or other such connector may be used to retrieve the end effector.
  • a wire rope, or other such connector may be wound on a spring tensioned spool, which may be motorized and/or manual.
  • a spring reel may be provided in several tension ranges to adapt to various tool or end effector weights.
  • the RMA comprises one or more hydraulic power units (HPU) to provide motive power for one or more hydraulic actuators.
  • hydraulic actuators include one or more of: elbow pivots, forearm extend, wrist pitch, wrist roll, and gripper open/close, among other things.
  • an HPU may be controlled automatically by the control system during operations.
  • the control system may automatically activate the hydraulic services upon a hydraulic service demand, and automatically control the HPU cooling system per hydraulic fluid temperature, in some embodiments.
  • An HPU may include basic manual controls, in addition to the automatic controls, for flexible control as needed. In some embodiments, local manual control for the HPU may be provided to allow for recovery in case of a control system failure.
  • the HPU supplies hydraulic oil to all the hydraulic actuators at a maximum pressure of 2.9 ksi and a maximum flow rate of 3.96 gallons per minute. Other pressures and flow rates are possible. In some embodiments, hydraulic fluid levels may be monitored to detect leakage.
  • the RMA comprises an integrated wash-down system that is designed to remove contaminants from the RMA.
  • wash-down occurs as the RMA is being retracted from the workspace thus capturing contaminants within the workspace.
  • the wash-down system may comprise one or more separate wash rings located within the RMA which allow pressurized water to be sprayed onto the RMA surfaces.
  • Some embodiments incorporate three wash rings wherein one is located at the top of the mast, one is located at the bottom of the mast, and one is located inside the forearm. During retrieval, each of the wash rings may be pressurized in a series of steps to ensure full cleaning of all components, in some embodiments.
  • a high-pressure water supply may be used to run the wash-down system.
  • the electrical componentry may be held to ingress protection (IP) 64 or higher to protect against overspray and fluids in the workspace.
  • IP ingress protection
  • all overspray and overflow may be captured by support frame containment covers and may drain from the bottom of a wash pan into the workspace. In the event of a drain blockage a float may automatically shut off the wash water in some embodiments.
  • Cables may run at least one of internally and externally to the RMA.
  • the term "cable” is intended to comprise electrical wiring, hydraulic hoses, pneumatic hoses, fiber optic cable, communications cable, or any other cables, wires, or lines as well as bundles thereof.
  • the cables may be used to transfer/transmit data pertaining to sensing and/or control in the system or any extensions attached to the system. Additionally, cables may be included for materials transfer into and out of the workspace.
  • One or more services may be routed internally through one or more of the mast, elbow, and forearm.
  • cable management may be accomplished using one or more of an external tensioned reel system, block-and-tackle system, and an internal cable chain.
  • a block-and-tackle system may be under constant tension using systems such as constant force gas springs in some embodiments.
  • additional umbilical cables may be included for tools requiring separate power or control systems or additional sensor or signaling cables.
  • the cable management system may allow cables to be feed in and out of the mast during extension and retraction, in some embodiments. This may be accomplished using a set of pulleys that may be tensioned with pneumatic cylinders, in some embodiments.
  • Some embodiments may comprise one or more cable shrouds to prevent lines and cables from being pinched during actuation.
  • An embodiment of a cable management system for the RMA may incorporate a RolaTube ® attached to a tether in proximity to the RMA similarly to the deployment/retrieval tool disclosed in co-pending application System and Method for Inspection and Maintenance of Hazardous Spaces, Ser. No. 15/341,985 filed November 2, 2016, with a priority date of November 3, 2015 , which is hereby incorporated by reference in its entirety.
  • Some embodiments may comprise and support a tether containing services and material transfer lines between sections. This may reduce forces required for tether movement and prevent entanglement with internal infrastructure in the workspace.
  • one or more sensors or other devices may utilize wireless communication technologies such near field communication (NFC) and Bluetooth, among others.
  • Wireless sensors and other devices may reduce the amount of cabling required thus increasing range, capability, and mobility of the system.
  • Control of the RMA is initiated by a control system.
  • the control system may be one of local and remote to the RMA and the operating space. Monitoring and control operations may be performed locally, remotely, and/or may be mobile. Mobile monitoring and control may be implemented using one or more mobile devices such as smart phones, laptops, moveable desktop computer work stations, tablets, and wearable computing devices. In some embodiments one or more operators may be equipped with one or more wearable devices, or other mobile devices, that provide feedback to the operator(s). For instance, a vibration and/or audible alert may be used to provide warnings to an operator.
  • control may be affected using a master-slave manipulation system including a "man-in-the-loop" system.
  • an operator may control a master system that is remote to the workspace.
  • the slave system (the RMA) may respond instantly and exactly.
  • One or more sensors located at least one of in the workspace and on the RMA may provide feedback to the operator.
  • one or more sensors on the RMA may provide haptic and other feedback to the operator to simulate any resistance or other forces acting on the RMA.
  • the RMA may not respond if the master directs it to perform a task that is not possible or will damage the RMA or the workspace.
  • the master may move to the extent of its range of motion or the workspace and no further.
  • Some embodiments may incorporate additional safety mechanisms such as the slave not responding if the master is moved too rapidly.
  • the master system is an exact replica, which may be scaled in size, of the slave system.
  • the master system is wearable, for instance on an operator's arm.
  • a preliminary inspection is performed prior to engaging in other operations. Preliminary inspections may yield data that may be used to pre-program the RMA to perform operations automatically. In some embodiments, operators may program an otherwise predetermined set of data into the RMA to perform operations automatically. In some embodiments, the workspace(s) may be inspected after operations for quality control or other purposes. The controls for the end effectors and/or tools may be integrated into the controls for the RMA and/or standalone.
  • the operating space is scanned using one or more sensors prior to operations to gather data which is used to generate an electronic three-dimensional map of the operating space.
  • the data is combined using known in the art sensor fusion techniques.
  • the three-dimensional map may be visible to the operator on a user interface and/or stored in memory.
  • the operator may set a global coordinate system and one or more local coordinate systems within the space.
  • the purpose of a three-dimensional map of the operating space is to define the boundaries of the operating space and any infrastructure or objects in the space that may restrict the RMA's range of motion in the space.
  • Knowledge of the geometry of the operating space may be used to pre-program the RMA to carry out operations automatically within the space and to avoid impact with objects in the space when carrying out operations manually.
  • One or more virtual barriers are generated to prevent equipment from contacting surfaces and/or objects in the operating space to protect the integrity of both the RMA and the operating space.
  • a three-dimensional map of the operating space defines the actual physical boundaries of the operating space.
  • Virtual barriers define one more virtual operating zones, offset from the physical boundaries, in which operations may be safely carried out in the operating space without damage to the space or to the RMA.
  • Virtual barriers are invisible "walls" generated either automatically by the control system using predetermined offset values and/or manually programmed or edited by an operator. Virtual barrier offset(s) may be programmed in a similar fashion as one would program the area of operations for a CNC machine.
  • an impermeable virtual barrier 905 may be offset from one or more of the surfaces 900a,b in the operating space 950 and may serve to prevent the RMA from advancing any closer to the one or more surfaces 900a,b.
  • an impermeable virtual barrier 905 is set at a minimum allowable distance from the one or more surfaces 900a,b at which operations may be safely performed.
  • virtual barriers are offset from a wall 900a and an object 900b in the operating space 950.
  • a permeable virtual barrier 915 is may offset from an impermeable virtual barrier 905 or from one or more surfaces 900a,b in the operating space 950 and may serve to provide haptic feedback and/or a warning to an operator when encountered.
  • the warning may be one of haptic, audial, and/or visual.
  • the warning may increase in intensity as the RMA moves farther into the permeable virtual barrier 915.
  • the haptic feedback may be in the form of resistance. For instance, as the RMA traverses through the permeable virtual barrier 915 the resistance may increase until the RMA encounters either an impermeable virtual barrier 905 or the resistance is insurmountable.
  • one or more virtual barriers may be generated automatically using predetermined values and/or manually generated by an operator. The offsets of the virtual barriers from surfaces and each other may be uniform throughout or variable. In the depicted embodiment the virtual barriers are offset farther from the object 900b than from the wall 900a. The one or more virtual barriers may be visible on a display.
  • the RMA 100 comprises one or more sensors 1700, one or more actuators 1730, one or more transceivers 1745, and a control system 1000.
  • the control system 1000 may comprise one or more processors 1710, one or more user interfaces 1720, one or more transceivers 1740, one or more programmable controllers 1750, a memory 1760, and one or more remote control stations 1770.
  • a programmable controller 1750 provides for a flexible means of manipulation of the RMA 100 and/or tools allowing for a best-fit control solution for the equipment.
  • the one or more remote control stations 1770 may provide custom operator interfaces.
  • the one or more interfaces 1720 may comprise one or more of displays, touchscreens, joysticks, buttons, toggles, switches, and voice input for equipment control.
  • the interface 1720 may be projected such that an operator may operate the RMA from inside a virtual 3D map of the operating space.
  • control system may require one or more forms of authentication from the operator in order to function. In some embodiments, if the control system loses confidence that an operator is properly authenticated, such as if it has not been tasked within a predetermined period, it may require the operator to re-authenticate.
  • control methods may comprise one or more of joint-by-joint actuation and inverse kinematic actuation. Inverse kinematics allows an operator to control the gripper/tool position, and the control system determines the joint movements to achieve that position.
  • control is operator-initiated individual variable speed joint control.
  • joint control may be either push-and-hold type or bump time-based type depending on the operation being performed.
  • control system 1000 may comprise a flexible and robust control interface.
  • the interface may comprise two or more modes of control providing appropriate control for the various normal and potential off normal operations of the equipment.
  • the primary design constraint that provides the ability for the control system 1000 to potentially perform various high level functions may be the integrated position feedback on the RMA axes.
  • the control system can perform inverse kinematic and kinematic calculations. Two basic modes of operation for the control system are joint control mode and inverse kinematic control mode.
  • joint control mode may provide an open-loop control for a singular axis.
  • An operator may select the desired axis to control on a control interface.
  • Control for the selected axis may be provided by a joystick, or other input device and/or interface.
  • Joint control mode may be used during recovery operations, calibration operations, and off-normal operations where the inverse kinematic control hinders the operator ability to perform a task.
  • Open loop joint control mode allows the removal of the RMA in the event of a position sensor failure.
  • closed-loop inverse kinematic control mode may provide simultaneous x/y/z control of a tool/end effecter to the operator.
  • Inverse kinematic control allows an operator to control the orientation of a tool/end effector relative to the floor, or other fixed infrastructure in the workspace, and allows the operator to control the position of the tool/end effector (Cartesian coordinate frames) inside the workspace.
  • the RMA and tools may be manually or automatically operated. In some embodiments, some functions are automatic and some are manual.
  • the RMA in some embodiments may offer variable speed control for each joint, with an overall adjustable maximum speed.
  • the RMA may comprise one or more interlocks to ensure efficient, proper, and safe equipment operations. In some embodiments, these interlocks vary in seriousness and indicated awareness to the operator. In some embodiments, there are three types of interlocks comprising alarms, warnings, and operational.
  • alarms may stop system operations that may risk equipment health and may generally cause some sort of display, haptic, and/or auditory feedback to an operator.
  • the control system alarm state may be visually displayed on an interface and status of the system alarms provided, in some embodiments.
  • alarms may require operator acknowledgement and resolution before the system can become operational again.
  • alarms may remain active and non-resettable if the existing alarm condition is active.
  • warnings may comprise display, haptic, and/or auditory feedback to an operator but may not cause the RMA to suspend operations.
  • Operational interlocks may be performed by the control system to ensure proper equipment health during normal operations. In some embodiments, operational interlocks may not be identified to an operator and are typically performed in the background. For example, a hydraulic power unit may integrate a cooling interlock that activates/deactivates a fan depending on the fluid temperature. This interlock may occur in the normal operating logic of the system.
  • control system may provide equipment interlocks as necessary (when considering desired control options and equipment feedback) to improve equipment health and operations.
  • control system interlocks may be segregated into three primary levels:
  • the control system may include an emergency stop system that removes all motive power from the equipment once tripped. In some embodiments, the emergency stop system does not remove power from the control and monitoring equipment. In some embodiments, an emergency stop system may allow for operational feedback during the emergency stop condition. After an emergency stop, the system may need to be reset by an operator to be functional. Although the equipment may stop or shut down, the control system may remain operational in some embodiments, which allows for alerts to occur and troubleshooting actions.
  • the control system design in some embodiments provides electrical disconnect switches at electrical service input points to allow for equipment isolation. The control system meets electrical standards to ensure equipment safety, and allows the electrical, hydraulic, and mechanical components to fail to a safe state upon the loss of services.
  • the RMA 100 comprises one or more sensors.
  • the one or more sensors may comprise one or more of contact sensors, non-contact sensors, capacitive sensors, inductive sensors, 3D imagers, cameras, thermal imagers, thermometers, pressure sensors, accelerometers, inertial measurement units (IMU), rotary encoders, resolvers, string encoders, radiation detectors, LIDAR, microphones, force sensors, load sensors, and strain sensors, among others.
  • one or more sensors may be used to determine the position of the deployed tools during operations.
  • one or more sensors may be used to monitor at least one of strain, torque, pressure, and environmental conditions at one or more locations in the system as a safety mechanism to prevent catastrophic failures.
  • the RMA 100 may include one or more imaging sensors.
  • the one or more imaging sensors may comprise one or more of 3D imaging, 2D range sensor, camera, thermal imager, and radiation detector, among others.
  • One or more imaging sensors may be used to provide inspection and monitoring capabilities for remote operators. Signals from one or more imaging sensors may be displayed in real-time, recorded for later review, and/or recorded for operational records.
  • one or more imagers may be mounted to, or in proximity to, an end effector to allow a close-up view of operations.
  • one or more imagers may be mounted in the workspace. Any one or more of the imagers may be one of fixed or pan-tilt-zoom types. Any one or more of the imagers may be controlled remotely by an operator or preset to follow input movement patterns or rules.
  • the operator may select and manage desired imager views for operations, while controlling the imagers with associated control features such as the pan, tilt, zoom (PTZ), focus, and lights.
  • one or more imagers may provide complete visual coverage of operations in the workspace.
  • One or more imagers may be used for visual collision avoidance during operations. Audio feedback to the operators may be provided from any one or more locations in the workspace and/or from one or more locations on the RMA 100.
  • One or more sensors may be included in the RMA 100 to detect contact with infrastructure and/or other surfaces in the workspace.
  • one or more sensors may be a six-axis sensor capable of relaying the direction and magnitude of an impact back to an operator and/or other personnel.
  • one or more sensors may serve as a proximity warning system to prevent contact with infrastructure and/or other surfaces in the workspace.
  • the control system will not process inputs that may damage the equipment or the workspace.
  • extension and/or velocity of extendable components in the system may be measured using one or more string potentiometers.
  • the mast rotate may be operated by an electric geared motor attached to a turntable bearing and use a resolver for position feedback, in some embodiments.
  • lighting may be provided at one or more locations in the workspace and/or at each imager position.
  • the RMA 100 comprises a dynamic measurement unit 1010 wherein the dynamic measurement unit 1010 comprises one or more accelerometers and one or more rate sensors.
  • the RMA 100 comprises one or more non-contact sensors affixed to at least one of the forearm 130, mast, and elbow.
  • a non-contact sensor is collocated with the dynamic measurement unit 1010 on the forearm 130.
  • a dynamic measurement unit 1010 may be configured as a six degree of freedom three axis sensor configured to operate in a Cartesian coordinate system.
  • the dynamic measurement unit 1010 comprises three accelerometers and three rate sensors where the accelerometers and rate sensors are paired and each pair is oriented along each axis in a Cartesian coordinate system.
  • one or more non-contact sensors (not depicted) affixed to at least one of the forearm 130, mast, and elbow report object measurements in the operating space in a polar reference frame, as range and azimuth or bearing to an object and/or surface.
  • the controller 1000 in some embodiments computes and displays the objects and/or surfaces in the operating space in a Cartesian reference frame of x, y, and z. This is done for the operator to present a more intuitive view of the operating space in three dimensions so it is it is easier to understand and visualize. Therefore, in some embodiments, the non-contact sensor data will be converted to the Cartesian reference frame before it is used.
  • r m and ⁇ m are the range and bearing, respectively, of the sensor target in the polar reference frame
  • x m and y m are the downrange and cross range coordinates, respectively, in the converted Cartesian reference frame.
  • R a 11 var x ⁇
  • r m , ⁇ m r m 2 e ⁇ 2 ⁇ ⁇ 2 sin 2 ⁇ m cosh 2 ⁇ ⁇ 2 ⁇ cosh ⁇ ⁇ 2 + cos 2 ⁇ m sinh 2 ⁇
  • the control system may power up in an equipment motive safe state in some embodiments.
  • the start-up of the equipment control may require operator initiation or emergency stop system reset and alarm reset at the operator interface. Operator initiation of the system may ensure that personnel are aware of the equipment status and state prior to operations.
  • control system may allow for the equipment to be shut down in a motive-safe state by the triggering of an emergency stop circuit.
  • the design of the control system in some embodiments ensures the equipment fails in a safe state upon the removal of motive power by emergency stop circuit or removal of electrical services.
  • a non-powered fail-safe design allows for a hard equipment shutdown, such as an electrical disconnect and isolation.
  • the control system may provide an off normal operations mode for recovery operations in the event of a failure.
  • Equipment recovery through the user interface may be the primary mode of equipment recovery for difficult to access operating areas. If the equipment cannot be recovered through the user interface (e.g., if the programmable controller failed), the operator may then implement a hydraulic or manual mechanical means for recovery.
  • any suitable means capable of performing the operations such as various hardware and/or software component(s), circuits, and/or module(s).
  • any operations illustrated in the Figures may be performed by corresponding functional means capable of performing the operations.
  • DSP digital signal processor
  • ASIC application specific integrated circuit
  • FPGA field programmable gate array signal
  • PLD programmable logic device
  • a general-purpose processor may be a microprocessor, but in the alternative, the processor may be any commercially available processor, controller, microcontroller or state machine.
  • a processor may also be implemented as a combination of two computing components, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
  • the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium.
  • Computer-readable media includes both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another.
  • a storage media may be any available media that can be accessed by a computer.
  • such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer.
  • any connection is properly termed a computer-readable medium.
  • the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave
  • the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium.
  • Disk and disc includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers.
  • a computer readable medium may comprise non-transitory computer readable medium (e.g., tangible media).
  • a computer readable medium may comprise transitory computer readable medium (e.g., a signal). Combinations of the above should also be included within the scope of computer-readable media.
  • a storage media may be any available media that can be accessed by a computer.
  • Such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer.
  • Disk and disc include compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk, and Blu-ray.RTM. disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers.

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  • Engineering & Computer Science (AREA)
  • Robotics (AREA)
  • Mechanical Engineering (AREA)
  • Human Computer Interaction (AREA)
  • Manipulator (AREA)
  • Length Measuring Devices With Unspecified Measuring Means (AREA)

Claims (15)

  1. Roboterarmsteuersystem, mit:
    einem Roboterarm (100), der so eingerichtet ist, dass er ein oder mehrere Werkzeuge (160) in einem Betriebsraum (950) einsetzt,
    einem oder mehreren Sensoren (1700) und
    einem Steuersystem (1000),
    dadurch gekennzeichnet, dass das Steuersystem (1000) wirkungsmäßig so eingerichtet ist, dass es:
    den Betriebsraum (950) mit dem einen oder den mehreren Sensoren (1700) abtastet, um eine oder mehrere Oberflächen (900a, 900b) zu erkennen, die den Betriebsraum (950) definieren,
    von dem einen oder den mehreren Sensoren (1700) empfangene Daten kombiniert,
    die kombinierten Daten zur Erzeugung einer dreidimensionalen Karte des Betriebsraums (950) verwendet, die zumindest teilweise auf der einen oder den mehreren Oberflächen (900a, 900b) beruht, die den Betriebsraum (950) definieren,
    eine undurchlässige virtuelle Sperre (905) errichtet, die von einer oder mehreren Oberflächen (900a, 900b) in dem Betriebsraum (950) versetzt ist, und
    eine durchlässige virtuelle Sperre (915) errichtet, die von der undurchlässigen virtuellen Sperre (905) versetzt ist.
  2. System nach Anspruch 1, bei dem der Versatz der undurchlässigen virtuellen Sperre (905) ein minimal zulässiger Abstand ist, in dem Arbeitsgänge durchgeführt werden können.
  3. System nach Anspruch 1, bei dem die undurchlässige virtuelle Sperre (905) verhindert, dass sich der Roboterarm (100) über sie hinaus vorbewegt.
  4. System nach Anspruch 1, bei dem die durchlässige virtuelle Sperre (915) dann, wenn auf sie gestoßen wird, eine Warnung an eine Bedienperson erzeugt.
  5. System nach Anspruch 4, bei dem die Warnung eine haptische Rückmeldung enthält.
  6. System nach Anspruch 5, bei dem die haptische Rückmeldung in Form von Widerstand gegen die Bewegung des Roboterarms (100) durch die Bedienperson erfolgt.
  7. System nach Anspruch 6, bei dem der Widerstand in dem Maße zunimmt, wie sich der Roboterarm (100) der undurchlässigen virtuellen Sperre (905) nähert, nachdem er auf die durchlässige virtuelle Sperre (915) gestoßen ist.
  8. System nach Anspruch 1, ferner mit einer Hauptsteuerung, die es einer Bedienperson ermöglicht, den Roboterarm (100) fernzusteuern.
  9. System nach Anspruch 1, bei dem der Versatz der undurchlässigen virtuellen Sperre (905) variabel und/oder gleichmäßig mit unterschiedlichen Abständen von der einen oder den mehreren Oberflächen (900a, 900b) ist.
  10. System nach Anspruch 1, bei dem der eine oder die mehreren Sensoren (1700) an bekannten Positionen am Roboterarm (100) befestigt sind.
  11. System nach Anspruch 1, ferner mit einer Benutzeroberfläche (1720), auf der einer Bedienperson die dreidimensionale Karte angezeigt wird.
  12. System nach Anspruch 1, bei dem der Roboterarm (100) wenigstens zwei Abschnitte (120, 130) umfasst, die über ein Winkelstück (140) miteinander verbunden sind.
  13. System nach Anspruch 12, bei dem ein erster Abschnitt (120) der wenigstens zwei Abschnitte (120, 130) wirkungsmäßig als vertikaler Mast ausgebildet ist und ein zweiter Abschnitt (130) der wenigstens zwei Abschnitte (120, 130) wirkungsmäßig zum Einsatz von Werkzeugen (160) von einem Arbeitsende des Roboterarms (100) aus ausgebildet ist.
  14. System nach Anspruch 12, bei dem der Roboterarm (100) einen vertikalen Mast (120) umfasst, der vertikal verstellbar ist.
  15. System nach Anspruch 12, bei dem jeder der beiden Abschnitte (120, 130) eine einstellbare Länge aufweist.
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US15/591,978 US10384353B2 (en) 2016-05-16 2017-05-10 System and method for a robotic manipulator system
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EP3266571A3 (de) 2018-04-11
JP7019919B2 (ja) 2022-02-16
US20170326737A1 (en) 2017-11-16
US10384353B2 (en) 2019-08-20
US20220048209A1 (en) 2022-02-17
JP2017209781A (ja) 2017-11-30
JP2022036252A (ja) 2022-03-04
EP3581344A1 (de) 2019-12-18
EP3266571B1 (de) 2019-07-10
US11571821B2 (en) 2023-02-07
US11192265B2 (en) 2021-12-07
US20190329426A1 (en) 2019-10-31
EP3970924A1 (de) 2022-03-23
EP3970924B1 (de) 2023-11-29
EP3266571A2 (de) 2018-01-10

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